Start-up instructions

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1 E l e k t r o n i k s y s t e m e G m b H Development and production of electronical systems Eichelreuth 13 Phone: Grassau Fax: info@rs-steiner.com Internet: Start-up instructions Electronic soft-starter Type: ESG..., ESG-I... Contents Page 1. General information Installation of the soft-starter ESG..., ESG-I Operation Meaning of the clamp connections Technical features of the control- and monitoring panel Switching suggestions Control and monitoring diagram Time control function module Current limitation Technical data Survey of the individual types Current transformer for ESG-I Load characteristics Frame sizes Version: 2016/07/13 1

2 1. General information The electronic motor-control devices ESG..., ESG-I... were developed for smooth and gentle startup and running of three-phase slip-ring or squirrel-cage induction motors. The electronic starting and running is basically effected by controlling the motor s electric potential with the help of thyristors. In order to achive a proper control or regulation process, three basic options are available: a) Variale voltage gradient (Standard usage): Starting and running is in this case effected by controlling motor voltage from zero to its final value within a time period that can be set by the user (p. 12). b) Current-limiting regulation: Running is controlled by electronic regulation of motor voltage. In this case the motor is accelerated with constant voltage to its rated speed (p. 14,15). c) Odometer regulation (Acceleration independent of load): With this regulation, linear acceleration to rated speed ist accomplished. A tachogenerator or an electronic revolution counter is necessary (actual-value counting by means of a tachogenerator or impulse counter). A large number of special solutions are available in addition to the presented function modules. The electronic starting device ESG..., ESG-I... is assembled modularly. It consists of three basic components: power element with cooling system and thyristor switching facility control unit with electronic starting and control system function module to determine starting method (current limitation, regulation by odometer or voltage gradient) 2

3 RS Elektroniksysteme GmbH - Electronic soft-starter ESG 2. Installation of the soft-starter ESG..., ESG-I... The built-in device according to with IP 23, must be mounted in a housing or switchboard panel. Take care that cooling is adequate (using separate ventilation, for example). The temperature must not exceed 50 C. The device is to be mounted on a vertical surface so that the ventilation duct from the cooler is also vertical. The devices should be installed in a relatively dry and dust-free space in order to function properly without any difficulties. Further conditions for the operating area: protection from dust and moisture protection from aggressive atmosphere free from vibration stable power conditions (especially at plants with large initial demand: P > 55 kw) No other components or construction units should be placed closer than mm from the device, so that airflow ventilation is not affected. The housing equipment (see IP 54) can be installed at operating locations which are not protected from dust and moisture. Wiring the Device: Make mains connections (L1, L2, L3) via fused circuit breakers with the usual safeguards. Simply connect the device to the motor supply lines; it desn t matter whether the motor is star or delta wired. The wiring for power supply and the wiring for control must be laid in separate conduits or shielded ducts. It is essential that the electrical installation comply with general stipulations of the VDE (German Electrical Engineers Association), specifically (VDE 0100, VDE 0113, VDE 160). 3

4 3. Operation To begin with, all electrical connections are to be made according to the accompanying wiring diagrams: L1, L2, L3, T1 (U), T2 (V), T3 (W). The electronic smooth-starting devices must be connected to the power supply in accord with VDE specifications so that they can be disconnected from the mains using a suitable switching means (i. e., master switch, contactor, protective power switch). Conduit installation: The mains power supply and motor power supply, as well as the control wiring, are to be in separate ducts or conduits. In order to avoid malfunctions it is advisable to install the electronic signal wiring separate from the power supply and/or protective control wiring and either to twist the feed and return signal lines or to use shielded control lines. Fuses: The mains fuse protection is dependent on the recommended or employed power-transmission cross-section, and must be carried out in accordance with DIN 57100, Part 430/VDE 0100 and part 430/6.81. Up until Type ESG 90, ESG-I 90, the devices possess no auxiliary semiconductor fuses. Suitable types may be selected from the table (see Appendix). Starting with type ESG 110, ESG-I 110, semi-conductor fuses for thyristor protection have been wired in series with them. Supervisory module (optional): The optional Supervisory module permits electronic control in regard to current excess, short circuits, asymmetric power distribution and motor temperature and provides a simultaneous LED indication corresponding to each malfunction report. The control electronics synchronously de-energizes the power driver portion. A start order (RESET) can return the device to operation as soon as the malfunction is eliminated. 4

5 4. Meaning of the clamp connections Clamp connections on the function module: These connections are found on all function modules with the same numeration. Auxiliary clamp connections are illustrated in each set of specific start-up instructions (see instructions for the standard module, current limiter, Tacho-Regulation or other modules). Generally speaking, two variants for initiating soft-start are possible: Standard activation: 1-2 starting and continuous operation ramp-down 3-4 n.c. closed open Activation with memory function 1-2 starting and continuous operation: short impulse 3-4 starting and continuous operation: closed 3-4 Auslauf geöffnet Special function 5-6 closing of power unit: closed ramp-up, continuous operation, open 5-6 ramp-down: Clamp connections on the control and monitoring panel: L1-N or connection to 230V/50-60Hz (standard) option: any other voltages can be realized upon request output switch terminal S output switch terminal S output switch terminal Fault input for PTC-resistor (thermal report sensor) 5

6 5. Technical features of the control- and monitoring panel The Control panel of the electronic smooth-starting devices ESG..., ESG-I... possesses various control and safety functions. As standard equipment, this panel is supplied with 230V/50-60 Hz via the clamps L1 and N, by which an internal DC voltage of 15 V is produced. On this control panel (Euroformat) is found a 100 x 75 mm interchangable function sub-panel which determines the behavior of the device when in operation Explaination of the LEDs on the control and function panel: LED 1 (red) LED 2 (red) LED 3 (red) LED 4 (green) Meaning: Temperature exceed of cooling or power element Reason: Overload, to high current, to high switching frequency. The threshold value of turning off is at 75 C. Meaning: Phase failure Reason: One or more phases are not connected with the mains connections L1, L2, L3 (Check the contacts!) Meaning: Temperature exceed of the load (PTC) Reason: Overstressing of the load Meaning: Auxiliary voltage connected (device in operation) If there is none of the explained malfunctions, all red LEDs have to go out by activating the device (e.g. by connecting the contacts 1-2 / reset procedure). LED SE LED S1 LED S2 Activation switching facility S1 actuated (contacts S1 and LED S1 are activated synchronously) switching facility S2 actuated (contacts S2 and LED S2 are activated synchronously) 6

7 6. Switching suggestions Using soft-starters of type ESG..., ESG-I... allows a great number of application possibilities which are all based on the initial conception. As examples, we demonstrate three fundamental connection diagrams which should give a survey of the device s integration in existing plants or those in the planning stage. It always depends on the user how the device should be installed in order to achieve the greatest effectiveness. The devices up to and including ESG 22, ESG-I 22 are designed for continuous operation, meaning that bridging (bypassing) the power driver portion is not necessary. For higher-performance devices (P > 22 kw) a bypass after a favorable full-run must be activated (i. e., S2 contact). Soft-start devices can also be supplied for continuous operation on request (option D ). Switching variations: A1 A2 A3 Fundamental electrical connection and starting-running activation via T1 or by means of an PLC output. By opening T1 ramp-down or switching off the device is initiated (minimal configuration). Page 8 Activation of ESG, ESG-I via T1 and T2. A short impulse with T1 (T2 closed) stores the Start command. In this version, by then briefly opening T2, ramp-down or switching off is initiated. Page 9 Activating the ESG, ESG-I via the main contactor. Page 10 ATTENTION! Be sure to see that the control voltage is turned on after or at the same time as the load voltage; otherwise the phase malfunction indication will be activated. This malfunction report can be cancelled by turning on the control voltage once again, or by bridging the clamps 1-2 (RE- SET function or respectively, start activation). 7

8 RS Elektroniksysteme GmbH - Electronic soft-starter ESG Switching suggestion A1 (standard) 8

9 RS Elektroniksysteme GmbH - Electronic soft-starter ESG Switching suggestion A2 9

10 RS Elektroniksysteme GmbH - Electronic soft-starter ESG Switching suggestion A3 By actuating switch T1 contact Q1 switches on 3-phase power to the soft-starting device and closes the starting contact. 10

11 7. Control and monitoring diagram Meaning og the LED indications: LED 1 temperature exceedance of heat sink LED 2 phase failure LED 3 temperature exceedance of motor If one of the listed malfunctions occurs, it will be recorded and the trouble report activated (clamps ). LED 4 auxiliary voltage on Auxiliary voltage S1 and S2: Optional interchangeable alternating contacts activated as per switching status shown. Switching status simultaneously indicated by LEDs S1, S2 on the function module. LED SE indicates the starting process (power rating: 5A, 250V/AC). 11

12 8. Time control function module t up adjustment of ramp-up time 0,5s-t max M up adjustment of starting torque 0-100% t down adjustment of ramp-down time 0,5s-t max M down adjustment of run-down torque (t max is set to 45s by default but can be modified arbitrarily) 0-100% extra equipment S Z Clamp connections: Soft-start is activated by closing (bridging) the terminal connections 1-2. They must remain bridged until smooth running or smooth cutoff is achieved. Another activation possibility can be realized with the help of connections 3-4.To do this, 3-4 must be bridged. Then a brief impulse between connections 1 and 2 initiates start-up. Opening clamps 3 4 effects slowdown to stop. Bridging the supplementary input clamps 5 6 turns off the power unit. ATTENTION! This supplementary input is only intended as a special function. After closing clamps 5-6 the previous function is consequently activated again. Therefore start contacts 1 and 2 have to be opened when opening

13 Time sequence of the switching functions: SE, S1 and S2 as well as LEDs SE, S1 and S2: SE: The SE LED lights when device is activated. For this the clamps 1 and 2 must be bridged. When the SE lights, the activation period is simultaneously indicated. S1: The S1 LED is active during the entire period of operation. At the same time the S1 contacts (14,15) are closed (for reporting purposes). Appearance of the function message current limiting signifies the application of electronic regulation. This LED can blink each time potential is applied. S2: The S2 LED shows the close of full-speed running. When this LED lights full-speed running is terminated. The auxiliary contacts 17 and 18 are simultaneously closed. (These contacts can be used for switching on bridging protection, for example). 13

14 9. Current limitation The current-limiting function panel serves to limit the starting current and to increase the starting period from start to full speed. First of all, all electrical connections as described in the corresponding passages must be performed. For power regulation, the actual values of motor current and voltage must be determined by a current converter. An arbitrary phase (L1, for example) can be utilized to fix and record the actual value of motor current. For the very first initial start-up, the dimmer or potentiometer must first be set at its leftpin position. The dimmer for the integral portion must be at its far-right pin position. If starting is now activated, the S1 LED indicator will flash. Now the dimmer must be turned slowly to the right to increase motor current until the motor starts to run. When electronic regulation is applied, the S1 indicator blends into steady illumination. By altering the integral portion, the regulator can react faster to current changes; however, under certain conditions this may cause uneven running. This adjustment should be carried out several times. Up to and including 7.5 kw, power control is effected by an internal transformer which must be led via the circuit L1. For ratings greater than 7.5 kw an external transformer is used as shown in illustration. Activation of smooth start takes place when clamps 1 2 are closed (bridged). These must remain bridged until smooth slowdown and stop or switching off takes place. Another possibility for activation can be attained with the help of clamps 3 4. In this case, clamps 3-4 must be bridged. A brief impulse across clamps 1-2 initiates starting. By opening clamps 3 4 slowdown to stop is performed. Shutting off the power unit is achieved by closing the auxiliary input clamps 5 6. Clamps 7-8 are used for the connection of an external current transformer. 14

15 Function module current limiting Generell possibilities of adjusting: Clamp connections: 1-2 start input 3-4 store function for impuls input on 1 and Abschaltung übergeordnet Potentiometers: t up ramp-up time (0-45s) t down ramp-down time (0-45s) I down ramp-down current I limit adjustment of current limitation integral dimension (in order Int to avoid uneven runs, the poti has to be set to its far-right pin position for motors > 11kW) Standard activation: rampup 1 and 2 closed rampdown 1 and 2 closed LED-indications SE activation (Start) output terminal switch S1 (active at t tot S1, rated operation and t down ) output terminal switch S2: active during rated operation S2 at the same time with LEDs S1 and S2 the corresponding auxiliary clamps are activated ** Annotation: The overall ramp-up time (t tot ) also depends on the current I limit. 15

16 10. Technical data Power supply 230V/50Hz standard Mains power 3-phase 230V 500V AC (+/-15%) Mains frequency 48-62Hz Rotary field self-synchronizing Kind of protection open design: IP23 Moisture class E according to DIN Built-in device VDE 0558 Built-in features vertical, electrical connections below Service condition indicators LEDs (SE, S1, S2, U h ) Ambient temperature 0-55 C Storage temperature -25 C-70 C Current limitation 0,5-4,5 of I n Failure indication phase failure, temperature of heat sink, lack of voltage, thyristor defect Control options for current, voltage, rotational speed Regulations DIN 40050, VBG4, DIN VDE 0160, DIN IEC 38, VDE 0110 CE-regulations EMC Directive 2014/30/EU LVD 2014/35/EU Installation altitude up to 1000m above sea level at rated load, 1% current reduction per 100m Test voltage according to VDE 0160 Tab. 6 Over voltage category ÜIII according to VDE (05/88) Pollution degree 1, IEC 664 Connection clamps or bus bars Errors and technical modifications excepted (Date: 2016/05) Options: braking module supervisory control module auxiliary voltage for 110V/400V/440V/500V AC or 24V/48V DC continuous operation for devices ESG 22 to ESG 90, ESG-I 22 to ESG-I 90 model IP54 analog control (0-10V, 4-20mA) Scontrol module for special ramp requirements creep-mode operation universal module (ESG M..) interface RS 232 bus connections for Interbus, Can-Bus and Profibus control using light conductors current monitoring in order to avoid short circuit (fast switch-off) 16

17 11. Survey of the individual types Type Motor power [kw] Max. starting current [A] Rec. semiconductor fuses [A] Mains fuse [A] Rec. crosssection [mm 2 ] Weight [kg] Frame size Dimensions WxHxD [mm] ESG 2,2/ESG-I 2,2 2, ,5 1,3 A 200x140x115 ESG 3/ESG-I 3 3, ,5 1,4 A 200x140x115 ESG 4/ESG-I 4 4, ,5 1,5 A 200x140x115 ESG 5,5/ESG-I 5,5 5, ,5 2,8 B 260x205x170 ESG 7,5/ESG-I 7,5 7, ,8 B 260x205x170 ESG 11/ESG-I 11 11, ,0 B 260x205x170 ESG 15/ESG-I 15 15, ,0 B 260x205x170 ESG 18,5/ESG-I 18,5 18, ,0 B 260x205x170 ESG 22/ESG-I 22 22, ,5 B 260x205x170 ESG 30/ESG-I 30 30, ,0 C 360x250x170 ESG 37/ESG-I 37 37, ,5 C 360x250x170 ESG 45/ESG-I 45 45, ,5 C 360x250x170 ESG 55/ESG-I 55 55, ,0 C 360x250x170 ESG 75/ESG-I 75 75, ,5 C 360x250x170 ESG 90/ESG-I 90 90, ,5 C 360x250x170 ESG 110/ESG-I , ,0 D 360x445x240 ESG 140/ESG-I , ,0 D 360x445x240 ESG 160/ESG-I , ,0 E 600x540x346 ESG 200/ESG-I , ,0 E 600x540x346 ESG 250/ESG-I , ,0 E 600x540x346 ESG 315/ESG-I , x185 42,0 E 600x540x346 ESG 355/ESG-I , x240 44,0 E 600x540x346 ESG 400/ESG-I , x300 51,0 F 850x725x495 ESG 560/ESG-I , x350 53,0 F 850x725x495 Errors and technical modifications excepted (Date: 2016/06) The given values are in reference to a rated operating voltage of 3x400 V. The values given for overload are valid for an ambient temperature of 40 C maximum and an installation altitude of 1000m maximum. The ratings given deal with values for standard motos accordng to IEC 72 and UNE

18 12. Current transformer for ESG-I Accessory for soft-start device type: ESG-I current limiting module Accessory for soft-start device type: ESG-M universal module This accessory is necessary for types ESG-I.. and ESG-M... starting with a 7,5 kw power rating. For lower ratings a transformer is an integral part of the regulator panel. Type Motorpower [kw] ESG-I respectively ESG-M item ESG-I item ESG-M STW 50:5 7,5 ESG-... 7,5 1 1 STW 75:5 11,0 ESG STW 75:5 15,0 ESG STW 100:5 18,5 ESG-...18,5 1 1 STW 100:5 22,0 ESG STW 200:5 30,0 ESG STW 200:5 37,0 ESG STW 200:5 45,0 ESG STW 200:5 55,0 ESG STW 300:5 75,0 ESG STW 400:5 90,0 ESG STW 400:5 110,0 ESG STW 400:5 140,0 ESG STW 500:5 160,0 ESG STW 750:5 200,0 ESG STW 1000:5 250,0 ESG STW 1000:5 315,0 ESG STW 1200:5 355,0 ESG STW 1500:5 400,0 ESG STW 2000:5 560,0 ESG Errors and technical modifications excepted (Date: 2008/08) Available current transformers can also be utilized, for example those employed for indicating motor current. For this they should be wired in series into the switching indicator circuit. The power transformer supplied with the ESG can also be installed for this purpose. 18

19 13. Load characteristics 19

20 20

21 14. Frame sizes Frame size: A 21

22 Frame size: B 22

23 Frame size: C 23

24 Frame size: D 24

25 Frame size: E 25

26 Frame size: F 26

Start-up instructions

Start-up instructions E l e k t r o n i k s y s t e m e G m b H Development and production of electronical systems Eichelreuth 13 Phone: +49 8641 598360 83224 Grassau Fax: +49 8641 598364 E-Mail: info@rs-steiner.com Internet:

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